Set up box and method for production thereof



Oct. 4, 1960 v A. J. VOHDEN 2,955,000

SET UP BOX AND METHOD FOR PRODUCTION THEREOF Filed Aug 4, 1958 2Sheets-Sheet 1 FIG 4 F462 5 INVENTUR ATTM- nQJ Oct. 4, 1960 Filed Aug.4. 1958 A. J. VOHDEN 2,955,000

SET UP BOX AND METHOD FOR PRODUCTION THEREOF 2 Sheets-Sheet 2 8 l5 ,1 QI Q Q OORQLVJNVENTOR.

BY Mi \5 w rates SET UP BOX AND METHOD FOR PRODUCTION THEREOF Filed Aug.4, 1958, Ser. No. 752,946

2Claims. (Cl.229-7) This invention relates to a set up box and to amethod for production thereof. More particularly the invention relatesto the production of set up paper boxes.

' It has heretofore been known to provide a set up paper box with an endflap adapted to be opened so that access may be gained to the contentsof said box via the end portion of the container. It has also been wellknown to provide folding boxes with this type of end flap. However, theconstruction of a folding box is readily distinguishable from that of aset up box, which distinction is to be noted since the present inventionis concerned with the latter form of container.

In producing a set up box the manufacturer is confronted with processproblems which are peculiar to the art of set up box manufacture. Theseproblems are not encountered by those producing folding boxes.

. A set up box, in contradistinction to a folding box, is provided withrigid corners. It is a further distinguishing feature of a set up boxthat it is fabricated from two basic pieces, i.e. a base portion and alid portion whereas a folding box is customarily produced from a singleblank of material.

An object of the present invention is to provide an improved andsimplified process for producing a set up paper box having a hinged endflap.

Another object of the invention is to provide an improved set up paperbox.

The set up box of the present invention, due to the process by which itis made is believed to exhibit superior moisture-resistant propertiesand is also visually more attractive than previously known set up boxespossessing hinged end flaps.

According to the present invention there is providedone end and saidside walls of said base portion being folded about and extendingperpendicularly from said lower panel to provide three fixed wallsurfaces, the second end wall of said base portion being adapted forfolding about a score line on said lower panel, said base portion beingdisposed within said lid portion such that when the box is in a closedposition the endand side walls of said base portion are adjacent to andin parallel relationship with the corresponding end and side walls ofsaid 'lid portion, a sheath of a wrapping material being provided on theouter surface of said lid portion extending about a plurality of edgesof the lower panel of said base portion and into sealing contacttherewith inorder to operatively connect said lid and base portions, aout being provided in each of the side walls of said lid portion topermit pivotalmovement of a segment of said lid 7 V,

latent 2 portion about a hinge score line on the surface of said upperpanel thereby providing said hinged end flap.

The present invention further provides a method for producing a set upbox having a hinged end flap, comprising providing a base portion byscoring a blank of sheet material to provide two pairs of parallel scorelines adjacent to and around the perimeter thereof to form asubstantially rectangular pattern, all of said score being imparted tothe same side of said sheet, removing the corner pieces of said sheetdefined by the intersection of said score lines, folding the sheet aboutsaid score lines to provide a lower panel and a pair of verticallyextending side Wall surfaces and a pair of end wall sur' faces, joiningsaid side walls to one of said end walls to form two rigid corners,providing a lid portion by scoring a second blank of sheet material toprovide two pairs of parallel score lines adjacent to and around theper-' irneter thereof to form a substantially rectangular pattern, allof said score lines being imparted to one side of said sheet, placingupon the other side of said second blank a hinge score line parallelwith but spaced from one end of said blank, removing the corner piecesof said sheet defined by the intersection of said two pairs of scorelines, folding said second blank about said two pairs of score lines toprovide an upper panel and a pair of verti cally extending end wallsurfaces and a pair of vertically extending side wall surfaces, joiningsaid end and side walls to form four rigid corners, placing about saidlid portion a sheath of substantially rectangularly shaped wrappingmaterial which has previously had the corners thereof mitered and anotch preferably V shaped in configuration cut into the marginal edgeportion of each side thereof an equal distance from an end of saidwrapping material, said notches having been made at a predeterminedposition in order to permit registration of said notches with the hingescore line on said lid portion, turning in the marginal edge portion ofsaid wrapping material which extends between said notches andabo'ut anend and a segment of each of the side walls of said lid portion whichsegments extend from said end to the hinge score line and securing saidturned in material to the inner surfaces of said end wall and side wallsegments, the marginal edge portion of the wrapping material which isnot turned in extending beyond the other end and remaining segments ofthe side walls of said lid portion parallel thereto, inserting said baseportion within said lid portion such that the end and side walls of saidbase portion are adjacent to and in parallel relationship with thecorresponding end and side walls of said lid portion, folding theunturned marginal edge portion of wrapping material into sealing contactwith the lower panel of said base portion to provide a completely closedbox, and cutting through each side wall of the lid portion at the hingescore line'to provide a hinged end flap. T

The invention will now be further described and illustrated withreference to the accompanying drawings of which:

Figure 1 is an isometric view of the completed set up box with the endflap in an open position;

Figures 2 and 3 are planned views of the sheet of starting material usedto form the lid portion of the box indicating the form which the sheettakes as the sequence of operations is performed upon said sheet;

Figure 4 is an isometric view of the base portion of the box ready forinsertion into the lid portion;

Figure 5 is an isometric view of the lid portion of the box adapted toreceive the base portion therein;

Figures 6-8 are planned views of the wrapping material and illustratethe changes in formwhich the wrap undergoes in being subjected to thesequence of process steps described hereinafter; i

1 Figure 10 is anisometric view of the set upbox after thewrap has beenfolded and secured to the base portion of the box,- the box being in acompletely closed condition prior to the final operational step ofcutting the side Walls or the lid portion to provide the box illustratedin Figure 1. I,

In the manufacture of a set up paper box it is conventional to fabricatethe base portion by scoring the initial board, which normally issupplied by the mill in sheet form, in a scoring machine. Two pairs ofparallel more lines are placed upon the sheet adjacent the edges thereofwith each of said pairs being. perpendicularly disposed with relation tothe other of said pairs. One or both pairs of score lines may be placedupon the sheet ina single operation depending upon the type of machinewhich is employed. However, all score lines are placed upon the sameside of the board. The board, provided with the two pairs of scores, isthen placed on a corner cutting machine which operates to remove thefour corner pieces of board defined by the intersection of the scorelines. Removal of these corner pieces permits the subsequent formationof the rigid corners of the box.

Following removal of the corner pieces the sheet is transportedto'either a single stayer or a quad stayer which operates upon the boardto fold a pair of the oppositely disposed marginal edges and one of theother edges about the scores. The machine glues a piece of stay paper orlike material to the two corners .of the base portion so-formed in sucha manner that two rigid corners result, The base portion with its tworigid corners is illustrated in Figure 4. It will be noted that one endstill remains loose and the other end and both sides of the base extendvertically from the plane of the sheet before the staying operation. Thematerial employed for the stay paper is customarily 90 lb. kraft whichhas been pre-gummed or may be kraft paper of a different weight whichhas a heat-seal adhesive coated upon the surface thereof. The baseportion of the box is now ready for insertion into the lid portion. HThe fabrication of the paper wrap will now be described with referenceto Figures 6#8 of the drawings. The paper is generally supplied by themillin the form of a roll although it is possible for the paper. to besupplied in sheets of the desired dimensions. Once the paper has beengiven the desireddimensions and is in substantially rectangular form itis inserted into a corner mitering machine to remove the corners of thesheet in order to eliminate the excess paper which would otherwise beexposed when the sheet is secured to the lid portion of the box in asubsequent step. At this stage of fabrication the paper sheet mayproperly be referred to as wrap 14 illustrated in Figure 6. Wrap 14 isthen provided with V notches 15 as shown in figure at oppositelydisposed marginal edge portions thereof. V-shape'd pieces of materialareremoved from the wrap during the notching procedure; The notches areplaced in the wrap at a point remote from the end thereof by apredetermined distance in order to provide proper alignment of thenotches with the location of the hinge score on the lid portion of thebox. The disposition of the hinge score onthe lid portion of the box tobe hereinafter described. Wrap 14 is then subjected to a further cuttingoperation in order to remove arelatively small section indication as 16in Figure 8 to facilitate folding of the wrap about the base portion inone of the final process steps. It is also within the scope of thisinvention to provide wrap 14 with the corner miters, V notches and cuts16 in a single operation as by employing a steel rule die on a cuttingpress.

The fabrication of the lid portion of the box will now be described withreference to Figures 2, 3 and of the drawings. The board is generally ofthe sam material as the material from which the base portion is formed,and may be chipboard, kraft, etc. These boards can vary in weight,finish and color. The only limitations as regards selection of theproper material are dictated by practical considerations and thus thematerial should be neither too thin nor too thickin-order to avoiddifiiculty in handling during the various manipulative steps of theprocess. The weight of the board may vary from 0.018 to 0.120 inch inthickness with the preferred caliper lying near the center of thisrange; Finishes in cardboard rangefrom very smooth to very rough and anyfinishcan be utilized for the materials employed in this invention.

The board intheform of a blank sheet is scored with 5 two pairs ofparallel scores 1 and 2 as shown in Figure 2.

' base portion and are subsequently removed in the same These scores maybe placed upon the board in the same manner as previously described inconnection with preparation of the base portion. It will be observedthat corner pieces 4 are formedby the intersection of the pairs ofscores 1 and 2. These corner pieces correspond to the corner pieceswhich were also formed in preparing the with prepascorewill bepositioned approximately one third of the distance from one end of thebox to the other end.

As indicated above the board, provided with scores 1, 2 and 3, is thensubjected to the known step of corner cutting in order to remove cornerpieces 4 therefrom. The board with the corner pieces removed isillustrated in Figure 3. 7

Board 7 is then placed in the single stayer or quad stayer describedhereinabove in connection with proparation of the base portion and-fourrigid corners are formed. It should be noted at this time that the baseportion is distinguished from the lid portion by. having only two rigidcorners whereas the lid portion has four such corners and also by thefact that the lid portion is provided with hinge score 3. The lidportion with its four rigid corners is depicted in Figure 5. The lidportion is now ready for combination with wrap14. It should be observedthat it is not essential to die cut the lid portion at the hinge scoreas is customary in previously known processes. By eliminating this stepthere is a resultant savings in time and expenseinvolved in the actualstep of cutting the lid portion and a further advantage ineliminatingthe need for aligning this cut in the lid portion with the notch 15 onwrap 14 when assembling the wrap and lid portion. A,further advantage isprovided in not cutting the lid portion. at the hinge score at this timesince the turning in by hand of the wrap around the cut in the lidportion isavoided in the situation where additional wrap material isprovided as has been customary where the art has attempted to avoid theproblems which arise in attempting to obtain exact registration of thecut in the lid portion and the cut in thewrap at the hinge score. Wrap14, mitered, notched and provided with end cut 16 which cut ispreferably of square configuration, is then fed to a gluer where a filmof an adhesive material is deposited on one surface thereof. The wrap,bearing the adhesive material thereon in an uncured or unset condition,is delivered to a wrapper such as the Stokes and Smith Wrapper. However,any of the known wrapping .m'achines may be employed and the Stokes andSmith into sealing contact with the outer surface of the upper panel.Turn-in sections 11, 12 and 13 of the wrap are folded about the openedges of the lid portion and into sealing engagement with the inside ofthe end and side wall surfaces lying between the hinge score line.Sections 8, 9 and of the wrap are folded about lid portion 18 and extendbeyond the edges in parallel relationship with the other end andremaining side wall segments of lid portion 18. Reference may be made toFigure 9 of the drawings at this point. It will be noted that the onlyportions of the marginal edges of wrap 14 which are turned in areportions extending from V cut miter to V out miter around the perimeterof what is destined to be the hinge end flap of the completed box.

Base portion 17 is then inserted into the lid portion and sections 8, 9and 10 are folded into sealing relationship with the bottom of baseportion 17 as shown in Figure 10 to result in a completely closed box.

The final step in production of the novel set up box comprisessubjecting the sides of the closed box to the operation of a cuttingdevice such as a table saw in order to cut the lid portion on each sidewall where score 3 appears, the cut being made to a depth suflicient toenable one to lift the hinge lid. Care is to be exercised during thecutting step in order to avoid marking the underlying base portion ofthe box. Proper regulation of the depth of out can avoid impropercutting. The completed box with the hinged end flap in an open positionis indicated as 19 in Figure 1. It will be observed that flap 5, whichis an end wall of base portion 17, is folded about its score line into avertical position so that it will register with the corresponding endwall of the lid portion when the box is closed. This flap can readily bepivoted about its score line in order to facilitate filling or emptyingof the box.

It is to be understood that a plurality of cutting devices such as tablesaws can be arranged to simultaneously provide the final cut at hingescore 3 in any number of boxes in order to mass produce the set upbox'of the present invention.

It has been discovered that, when employing a table saw to eifect thefinal cut, by reversing the direction in which the teeth of the tablesaw blade are disposed the operator can obtain a smooth finished cut ascontrasted with a slightly burred out which results from utilizing atable saw in the conventional manner.

As will be well understood by those skilled in the art of set up boxmanufacture, an angle out can be made as the final cut in order toprovide the hinged end flap although a straight cut as illustrated inFigure 1 is preferred at the present time.

It is also within the scope of the present invention to provide a liningfor the entire box in addition to or in substitution of wrap 14, thepreferred embodiment comprising the use of wrap 14 merely for the lidportion as has been hereinabove described. Polyethylene may, if desired,be utilized as either the liner or as wrap 14. Also, the base portionmay be lined in the manner well known to those skilled in the art inaddition to provid- 6 ing wrap 14 for the lid portion. Further, dividersor partitions can be inserted into the box prior to its being sealed orafter the final cut is made at the hinge score line in the side Walls ofthe lid portion.

While certain novel features of the invention have been disclosed andare pointed out in the claims annexed hereto, it will be understood thatvarious omissions, substitutions and changes may be made by thoseskilled in the art without departing from the spirit and scope of theinvention.

What I claim is:

1. A set up box having a hinged end flap, comprising a lid portion and abase portion disposed Within and operatively connected to said lidportion, said lid portion being formed from a blank of material toprovide an upper panel having integral end and side wall surfaces foldedthereabout to extend perpendicularly therefrom, said base portion beingformed from a'second blank of material to provide a lower panel havingintegral end and side wall surfaces, one end and said side walls of saidbase portion being folded about and extending perpendicularly from saidlower panel to provide three fixed wall surfaces, the second end wall ofsaid base portion being adapted for folding about a score line on saidlower panel, said base portion being disposed Within said lid portionsuch that when the box is in a closed position the ends and side wallsof said base portion are adjacent to and in parallel relationship withthe corresponding ends and side walls of said lid portion, a sheath of awrapping material being provided on the entire outer surface of said lidportion extending about a plurality of edges of the lower panel of saidbase portion and into sealing contact therewith in order to operativelyconnect said lid and base portions, a cut being provided in each of theside walls of said lid portion subsequent to application of saidwrapping material to said lid portion to permit pivotal movement of asegment of said lid portion about a hinge score line on the surface ofsaid upper panel thereby providing said hinged end flap.

2. A set up box according to claim 1, wherein said sheath of wrappingmaterial is turned under and secured to the inner surfaces of the endand side wall portions of said lid portion which form the hinged endflap, said wrapping material having marginal edge portions thereofextending about the lower panel of said base portion to form asubstantially U-shaped sealing surface.

References Cited in the file of this patent UNITED STATES PATENTS466,479 Winchester Jan. 5, 1892 1,641,861 Moss Sept. 6, 1927 1,769,596Neidich July 1, 1930 1,797,941 Carle Mar. 24, 1931 1,895,070 CzerwenyJan. 24, 1933 2,147,614 Sidebotham Feb. 14, 1939 2,581,615 Whitelaw Jan.8, 1952 2,604,253 Turner July 22, 1952

